WO2021247502A1

WO2021247502A1 - Hybrid system for modular construction of concrete buildings

Info

Publication number: WO2021247502A1
Application number: PCT/US2021/035148
Authority: WO
Inventors: Justin SLADE
Original assignee: Slade Justin
Priority date: 2020-06-02
Filing date: 2021-06-01
Publication date: 2021-12-09

Abstract

A method which relates to the modular construction of buildings and structural concrete systems. The subject invention discloses a hybrid system using prefabricated modular units and structural concrete. The prefab modules are stacked or placed together. The shape of the modules creates voids to allow for structural columns, walls, and floor systems. Concrete is poured and distributed on-site to fill the voids and creates the structural system of the building. Poured-in-place concrete is the primary structural component of the system. The design of modules may also contribute to the structural system of the building. The system allows for a variety of materials for the fabrication of modules which may include but is not limited to concrete, structural steel, light gauge steel, wood, and composites. Although this method can be used for single-story buildings, it may also be implemented for construction of multi-story buildings including mid-rise and high-rise buildings.

Description

HYBRID SYSTEM FOR MODULAR CONSTRUCTION OF CONCRETE BUILDINGS

TECHNICAL FIELD

The subject invention relates to methods for the construction of buildings using prefabricated modular components. This also relates to construction methods using structural concrete systems.

BACKGROUND ART

One method which allows for vertical construction using volumetric/3D modular systems involves structural steel modules which are fastened together to construct the building. US Patent, 10941561B2 discloses a system which uses prefabricated modules made with structural steel and moment connections bolted together on-site. US Patent, 9458619B2 discloses a connection system for prefabricated steel modules to be connected on-site. This method of construction requires the modules to be extremely robust with structural steel cages creating a volumetric module. These modules then become extensive to build and manufacture. Although on-site efficiencies are obtained with these prefabricated modules, the overall efficiency of the system does not always provide substantial benefits when compared to conventional ground-up structural systems. This system also places limitations on the structural design of the building.

Other methods for the construction of buildings with modular components involve using precast concrete. US Patent, 9371648B1 discloses precast concrete pieces when placed together on-site provide the formwork for the floor system, then concrete is poured on-site to fill the forms. This system involves both precast concrete and poured on-site concrete which provides some building efficiency, however, the overall efficiencies are not substantial enough for the building as a whole. All other aspects of the building such as interior walls, electrical systems, and finishes involve conventional construction methods.

China Patent, 105370039A discloses prefabricated volumetric concrete modules which are stacked on-site and grouted together with mortar. The structural system of the building is achieved by the combination of precast concrete modules and mortar poured on-site to connect the modules. This method is likely more efficient than the previous mentioned method, however, this method has several limitations. Since the module floor, walls, and ceiling are fabricated with precast concrete, the weight of the modules is extensive. As a result, the weight minimizes and limits the size and shape of the modules. The manufacturing and transport of these modules is also cumbersome and inefficient.

Another method US Patent, 7185467B2 discloses use of precast GRC (Glass Reinforced Concrete) 2D panels which are formed in a factory, then brought to the site and placed together to create the formwork for the building. Concrete is then poured on-site to create the structural system of the building. This method provides efficiencies for building with concrete since the precast GRC panels are left in place and may become the finished walls and ceilings for the building. The disadvantage of this system is that 2D panels require more labor to install on-site, as opposed to 3D modules which are assembled in the factory. Also, this system relies on GRC panels which is more expensive to manufacture when compared to other materials, such as light gauge steel walls.

Although prefabricated buildings, such as those mentioned above, have effectively shortened the time frame to construct, building efficiencies are not always substantial when compared to conventional construction methods. For prefabricated buildings to be viable on a wide scale, it is necessary that they not only save time but also must provide overall building efficiencies which provide savings to hard construction costs for the complete building.

For multi-story buildings, the structural components for prefabricated modules add a substantial cost to the building. Although some efficiencies are obtained with the above prefabricated systems, current structural systems for multi-story modular buildings are often costly to fabricate and lack substantial building efficiency.

DISCLOSURE OF INVENTION

The present invention discloses a system which allows for the construction of buildings using prefabricated modular methods in conjunction with on-site concrete methods. Modules prefabricated in a factory are designed to be used synergistically with structural concrete systems. The shape and spacing of the prefab modules create the formwork for structural concrete to be poured on-site.

As opposed to connecting prefabricated modules for structural strength, this method implores a hybrid approach to the building assembly. The structural system is all or partially constructed on-site. The primary components of the building such as walls, finishes, electrical systems and plumbing systems are assembled in a factory. The advantage of this method is to allow for a more efficient building process for both the structural system and the prefabricated modules. Another advantage for this method is to allow greater flexibility in the design of the building. Because the modules for this system do not represent fully integrated structural members, it allows. for a variety of design configurations and manufacturing flexibility which otherwise would not be feasible. By building all or a portion of the structural system on-site, the system allows the off-site prefabrication of the modules to be manufactured in an efficient manner with the most cost-effective materials.

Prefabricated modules for this system consist of 3D volumetric modules which may be prefinished or partially finished. 2D modules or panels may also be incorporated into the system. A variety of materials may be used to fabricate the modules to include but not limited to concrete, structural steel, light gauge steel, wood, and synthetic composites. The prefabricated modules may contribute to the structural system of the building or may be separate from the structural system of the building.

The prefab modules are brought to the project site and stacked or placed together. The shape and spacing of the modules create voids to allow for columns, walls, and floor slabs. Concrete is then poured and distributed to fill the voids and thereby creates the structural system of the building.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a multi-story building showing the hybrid method of constructing with volumetric modular units and a poured-in-place concrete.

FIG. 2 is a volumetric modular component used for the system.

FIG. 3 is the detail of floor system cross-section for the system.

FIG. 4 shows how concrete is distributed to pour columns and walls

FIG. 5 shows an example of how concrete may be distributed for the floor system through column voids

FIG. 6 shows another example of how concrete may be distributed to the floor system through openings in the module floor

REFERENCE NUMERALS FOR DRAWINGS

11 prefab volumetric modular unit

12 concrete slab poured on-site

13 concrete column

14 rebar for column

15 column rebar extending from floor below

16 rebar for sheer wall

17 wall jog to create void for wall

18 wall jog to create void for column

19 void for concrete slab or deck

20 void for column

22 wall of volumetric module

23 precast concrete slab of module

24 lattice rebar in precast slab

25 stand or spacer

28 pop-out

29 window

31 horizontal rebar at prefab slab 32 horizontal rebar at on-site floor

33 ceiling system of volumetric modular unit

40 concrete pump boom base

41 hose end of concrete pump

42 self-consolidating concrete

BEST MODE FOR CARRYING OUT THE INVENTION

FIG. 1 is a multi-story building showing the hybrid method of constructing with volumetric modular units and poured-in-place concrete. The volumetric units 11 are stacked next to and on top of each other. The reinforced steel rebar for floors, walls, and columns, 14, 15,

16 are installed as floors proceed horizontally and vertically. Jogs in the walls of the modules create voids for columns 18 and walls 17. The voids are filled with concrete as construction progresses vertically.

The key operation of this method is to allow for the structural components of the building to be poured on-site, such as columns, walls, and floors while congruently building with prefabricated volumetric modules. The shoring and the forming, normally required in a conventional poured-in-place concrete building, is resolved by the shape of the modules. With this hybrid method, the modules become the forms. The jogs in the walls, 17 and 18 create the forming necessary for pouring the concrete columns and walls, so when placed together, little or no additional forming is necessary to pour columns 13 and sheer walls 16. The concrete floor or deck 12 may be poured before or after the placement of the modules. By pouring the deck after modules are placed may allow for more building efficiency, since the modules also create the formwork for the deck. When pouring the deck, the ceiling system from the modules below create the primary shoring and forms necessary for pouring the deck. The shoring may also be resolved with additional jacks or reinforcement panels placed on top of modules.

FIG. 2 is a view of a 3D volumetric modular unit that may be used with the system. The floor 23 of this example is a prefabricated concrete slab with structural rebar 24 partially poured into the slab. The precast slab is fabricated by filling a mold with concrete so the rebar components 24 are partially exposed. Once the concrete substantially cures, the slab is turned over and the walls are then constructed on the slab to create a volumetric module. The walls of the modular 22 can be constructed with a variety of materials depending on the project requirements such as wood, concrete, or light gauge steel studs. The jogs in the wall 26 and 27 provide the forming where necessary for columns and walls. The jogs can be created by the shape of the module walls, or they can be formed by pop-outs 28 using foam or other materials. Once craned into place the module sits on stands or spacers 25 attached to the floor system which rests on the modular units below. These modules may be finished volumetric modules with interior walls, electrical, interior finishes, exterior finishes, and windows 29. A building can be designed to be structurally independent of the modules, or the structural system can also be incorporated with the prefabricated 3D modules. The example of FIG. 2 shows how the floor system of the module may contribute to the structural system of the building floor system. FIG. 3 is a detail of the floor section for the module used in FIG. 2. Prior to setting the module, reinforcement steel 32 is installed as necessary. The module is then set in place. The precast slab of the module 23 with reinforcement 31 and rebar 24 is partially exposed. The ceiling system of the module below 33 acts as shoring for the floor deck above. After the modules are set in place, the concrete slab 12 is poured.

FIG.4 shows a method to distribute concrete throughout the building. After reinforcement steel 14 is tied and the modules 11 are stacked, a concrete pump with a boom 40 and hose 41 are used to distribute concrete throughout the building as necessary.

FIG. 5 shows how concrete may be distributed under the modules 11 by pouring concrete through voids where walls and columns 18 are located. Spacers 25 create a void 19 between the modules to allow for distribution of concrete 42 below the module using a concrete pumping system 41. Self-consolidating concrete allows concrete to move around rebar 14 and adequately move under the module. In this example, the column void 18 provides the opening to distribute concrete. The column below 13 was previously poured when placing the modules 11 below.

FIG. 6 shows how concrete may also be poured through openings 32 in the module floor. In this example, openings 32 in the floor are strategically designed and built into the module floor system in the factory. After modules 11 are brought to the site and stacked, concrete is then distributed below the module with a concrete pump 41. Openings in the module floor may also be used to inspect and view concrete being distributed to determine concrete levels and consolidation. Other methods to inspect concrete under modules may include GPR devices (ground penetrating radar). Self-consolidating concrete and rebar shakers/vibrators may be used to assist with concrete distribution to allow for movement and consolidation of concrete.

INDUSTRIAL APPLICABILITY

The hybrid system can be used for a variety of building types including residential, office, hospitality, student housing, and mixed-use. The system allows for a variety of configurations based on the design of the building, and may allow for more unique or irregular designs, where other modular systems may be limited. A variety of materials can be used to fabricate the modules depending on the cost and availability of materials in different markets. The system is applicable to mid-rise and high-rise buildings. Although this method is effective for multi-story buildings, the same method can be used for single story buildings, whether post-and-beam or slab-on-grade.

Claims

CLAIM

A hybrid system for the construction of buildings using prefabricated modules and structural poured-in-place concrete, in the following method: a. Volumetric 3D modules and/or 2D modules are prefabricated off-site. b. Said modules are transported to the construction site and stacked or placed together. c. Said modules when placed together create voids for columns, walls, and floor systems to allow for a reinforced poured-in-place concrete system, whereby minimizing the amount of formwork for said concrete system. d. Said concrete system is poured in stages as the building process progresses vertically and creates the primary structural system of the building.